Well thanks to the help of this msg board, I did some major work last night.
First thing was thermo sending unit that has kept me off the trails for a month while I waited for the right part. First, they sent the wrong thermo switch. The Yamaha diagrams have are wrong on the 2002 Grizzly 660. They mistakenly switched the part numbers on the diagram for the two thermo switches. Result was I got the wrong thermo in a bag with what the diagram says is the right part number. I can't believe in 3 years that I was the first person to realise this and it was never fixed before. Anyway, another week of waiting and I finally got the right one. Now on to fixing.. Well, we take the front hood off and remove the radiator cap and there is barely any coolant. We fill up with water and I see it pouring out by the left footrest. I get underneath and see a 1/2 inch stick right into the hose. Turns out, I hit this stick about 100 yrds from my house the last ride and all the fluid drained so quickly that the overflow resevoir still showed a full level. Then when I parked the quad in the garage, there was no fluid left to leak out so I never realized I had a leak!!! I followed all the diagnostics, but instead of taking the hood off and checking the radiator I assumed there was coolant because of the overflow resevoir.. DOH! The reason the thermo switch didnt turn the fan on is that it was not immersed in any coolant... Then 4 weeks later trying to get the stupid part and I dont need it after all!!! Now I have to wait one more week for the lower radiator hose... man I feel dumb! Shortcuts wasted a month of riding!
Next I did the valve adjustment. Suprisingly, they were not bad. The exhaust valves were right on the money and the intake valves were near the low end of the specifications so we adjusted them to the middle of specs. All in all they were very good considering no adjustment ever done and it has 185 hours and 1250 miles. Two notes on my experience.
Aligning TDC - There are actually 3 marks on the crankshaft! What was Yamaha thinking?!?! They say to align the I mark with the notch and then they put 3 marks on wheel. The first two marks (if rotating counter clockwise like the manual says) are connected with a line, while the third line is a stand alone mark. Our gut feeling was the 3rd line which is by itself, but to be sure we checked the piston position thru the spark plug hole and indeed it was the third line.
We were able to adjust the valves without removing the front fender. It was a pain and very difficult to see, but with two friends help, a mirror and light, I was able to sneak my head in far enough to check the exhaust valves. Luckily they were within specs... I am not sure how well we would have been able to adjust them with the fender still one and limited access.
Well, thats all for now. I hope to take some ride pics when I finally get back there!
Jim
First thing was thermo sending unit that has kept me off the trails for a month while I waited for the right part. First, they sent the wrong thermo switch. The Yamaha diagrams have are wrong on the 2002 Grizzly 660. They mistakenly switched the part numbers on the diagram for the two thermo switches. Result was I got the wrong thermo in a bag with what the diagram says is the right part number. I can't believe in 3 years that I was the first person to realise this and it was never fixed before. Anyway, another week of waiting and I finally got the right one. Now on to fixing.. Well, we take the front hood off and remove the radiator cap and there is barely any coolant. We fill up with water and I see it pouring out by the left footrest. I get underneath and see a 1/2 inch stick right into the hose. Turns out, I hit this stick about 100 yrds from my house the last ride and all the fluid drained so quickly that the overflow resevoir still showed a full level. Then when I parked the quad in the garage, there was no fluid left to leak out so I never realized I had a leak!!! I followed all the diagnostics, but instead of taking the hood off and checking the radiator I assumed there was coolant because of the overflow resevoir.. DOH! The reason the thermo switch didnt turn the fan on is that it was not immersed in any coolant... Then 4 weeks later trying to get the stupid part and I dont need it after all!!! Now I have to wait one more week for the lower radiator hose... man I feel dumb! Shortcuts wasted a month of riding!
Next I did the valve adjustment. Suprisingly, they were not bad. The exhaust valves were right on the money and the intake valves were near the low end of the specifications so we adjusted them to the middle of specs. All in all they were very good considering no adjustment ever done and it has 185 hours and 1250 miles. Two notes on my experience.
Aligning TDC - There are actually 3 marks on the crankshaft! What was Yamaha thinking?!?! They say to align the I mark with the notch and then they put 3 marks on wheel. The first two marks (if rotating counter clockwise like the manual says) are connected with a line, while the third line is a stand alone mark. Our gut feeling was the 3rd line which is by itself, but to be sure we checked the piston position thru the spark plug hole and indeed it was the third line.
We were able to adjust the valves without removing the front fender. It was a pain and very difficult to see, but with two friends help, a mirror and light, I was able to sneak my head in far enough to check the exhaust valves. Luckily they were within specs... I am not sure how well we would have been able to adjust them with the fender still one and limited access.
Well, thats all for now. I hope to take some ride pics when I finally get back there!
Jim
